Career Blade Industrial-Maintenance-Maintaining-Equipment
INDUSTRIAL MAINTENANCE: MAINTAINING EQUIPMENT
LESSON PLAN OVERVIEW
Career: Industrial Machinery Mechanics maintain and repair factory equipment and other industrial machinery, such as conveying systems, production machinery, and packaging equipment.
Lesson: This lesson plan includes ways to introduce students to the career of an Industrial Machinery Mechanic by analyzing maintenance and repair costs versus replacing equipment and demonstrate the skills an Industrial Machinery Mechanic uses to keep industrial equipment working properly to avoid a shutdown and meet production goals.
Grade Level: High School
Learning Objectives:
〉 Students will explore the career of an Industrial Machinery Mechanic and how they analyze maintenance and repair costs versus replacement costs to make maintenance decisions.
〉 Students will disassemble and reassemble a piece of equipment and identify the parts to better understand the mechanics that make the machine work.
〉 Students will gain an insight into the Industrial Machinery Mechanic career, including common job tasks, salary, career pathway, and credentials required to perform the job.
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〉 An old machine or appliance – computer, clock, radio, etc.
Lesson Instructions: This lesson plan will help you demonstrate to students common skills and procedures used in the industrial maintenance profession. Begin the lesson by reading the Class Message below to your students, then have them watch the recommended Video Introduction. Afterwards, facilitate discussion with the Class Questions listed.
After the discussion, students will work on the included activities. Each activity has a printable worksheet with student instructions and areas to record their work. Have students read their worksheets before beginning each activity.
You should also familiarize yourself with the student worksheets to help demonstrate any procedures and help facilitate the ending activity discussion .
Class Message: Today we are going to explore some of the responsibilities and duties of an Industrial Machinery Mechanic, which is a career within the Manufacturing industry. An Industrial Machinery Mechanic’s job is to ensure that all equipment, tools, and machinery are properly calibrated and maintained to prevent shutdowns and meet production goals.
Industrial Machinery Mechanics maintain and repair factory equipment and other industrial machinery, such as conveying systems, production machinery, and packaging equipment.
In this lesson, we will discuss some common Industrial Machinery Mechanic tasks, such as analyzing the cost to replace a piece of equipment versus repair, and will have the opportunity to disassemble and reassemble a machine or appliance to understand the mechanics that make the machine work.
Let’s watch this brief video to better understand the career of an Industrial Machinery Mechanic and how they affect our everyday lives.
Class Discussion Questions:
〉 Think about a car manufacturing plant and all of the parts it takes to assemble the final product, what do you think would happen if a piece of machinery stopped working or malfunctioned during a shift?
〉 If an assembly line is temporarily shut down, how does it affect production and costs?
〉 What are some of the problems an Industrial Machinery Mechanic may encounter on a daily basis that could affect production?
Activities Overview: This lesson plan includes two student activities. In Activity #1, students will analyze data to determine whether to repair or replace trucks used to deliver products to customers. In Activity #2, students will disassemble and reassemble a machine or appliance to understand the mechanics that make the machine work.
Read and familiarize yourself with the student worksheet for each activity
Activity #1: Why Machines Need Maintenance
Students will analyze data to determine whether to repair or replace trucks used to deliver products to customers.
Activity Instructions:
〉 Hand out the student worksheet.
〉 Facilitate introduction of activity.
〉 After completion, facilitate discussion questions for this activity
Activity Results:
Refer to the Repair Costs and Depreciation Costs graphs to answer these questions.
〉 In general, the company will spend the most amount of money to keep their trucks running when they are how many years old? 7 years
〉 The company wants to buy a new truck, they are considering the following trucks:
Delivery Van, 5 years old
Box Truck, 5 years old
Semi-Truck, 3 years old
Delivery Van, 3 years old
Since money might be tight for the next few years, the company wants the truck that will have the lowest repair costs for the next three years.
〉 The company has two Semi-Trucks, but needs to sell one. One is six years old and the other is eight years old. The company wants to keep the semi-truck that is past its year of highest total cost.
Consider both repair and depreciation costs and how it affects the company’s total worth. Which car, if any, should the company keep? - Eight-year-old semi-truck
The statements below are conclusions you might draw from the Repair Costs and Depreciation Costs graphs. Fill in the blank to complete each conclusion:
A truck loses most of its value in around the first 3 years.
Most major truck repairs occur after the truck is 5 years old. Which truck loses more value in the first year than the Box Truck. - Semi-Truck
Activity Questions:
〉 Did you find it easy or difficult to analyze the information in the diagrams to answer the questions? - Allow students to share their experience.
〉 What are some of the factors a company should consider when making the decision to repair or replace a piece of equipment? - Possible responses: considered the cost of down time to repair vs cost of replacing, considered how it would affect production costs, compared renting equipment versus purchasing new equipment, etc.
〉 How do you think machinery repairs and replacement costs affect the overall production of the product? - Possible responses: the cost of repair and replacement is factored into the cost of the product, the cost of repair/replacement is transferred to the price the customer pays for the product, etc.
Activity #2: Disassemble & Reassemble Equipment
This activity challenges students to disassemble and reassemble an old machine or appliance.
Activity Instructions:
〉 Hand out the student worksheet.
〉 Assign students into groups of 4-5.
〉 Facilitate introduction of activity.
〉 Walk students through the instructions for the activity.
〉 After completion, facilitate discussion question for this activity.
Activity Results:
In teams, students disassembled and reassembled an old machine or appliance. Students identified what the device is, what it is used for, drew a sketch of the device, and documented the steps to disassemble the device, and then followed the steps to reassemble the device
Activity Discussion:
〉 How do you think this activity demonstrated the job of an Industrial Machinery Mechanic? - Possible responses: we were able to take a piece of equipment apart and then put it back together, we were able to dissect a machine to see what it looked like and how it operates, etc.
〉 Were you able to easily disassemble the machine and put it back together? If not, why? - Allow groups to share their experience.
〉 How do you think Industrial Machinery Mechanics know how to disassemble, diagnosis, repair, and reassemble machinery? - Possible responses: through training and experience, trial and error, testing and analyzing the parts to determine what is malfunctioning, etc.
CAREER INSIGHT
Career Highlight: This lesson plan highlights some of the skills an Industrial Machinery Mechanic uses on a daily basis to maintain industrial equipment, tools, and machinery. See Employers in My Area section to contact businesses and organizations in your area about classroom demonstrations, on-site visits, or other additional career exposure opportunities.
Featured Career:
Industrial Machinery Mechanic
Career Descriptions: Industrial machinery mechanics and machinery maintenance workers maintain and repair factory equipment and other industrial machinery, such as conveying systems, production machinery, and packaging equipment.
Industrial machinery mechanics, machinery maintenance workers, and millwrights typically do the following:
〉 Read technical manuals to understand equipment and controls
〉 Disassemble machinery and equipment when there is a problem
〉 Repair or replace broken or malfunctioning components
〉 Perform tests and run initial batches to make sure that the machine is running smoothly
〉 Detect minor problems by performing basic diagnostic tests
〉 Test malfunctioning machinery to determine whether major repairs are needed
〉 Adjust and calibrate equipment and machinery to optimal specifications
〉 Clean and lubricate equipment or machinery
〉 Move machinery and equipment
Industrial machinery mechanics, also called maintenance machinists, keep machines in working order by detecting and correcting errors before the machine or the products it produces are damaged. Many of these machines are increasingly run by computers.
Other Names for this Career: Industrial Machinery Mechanic, Industrial Mechanic, Mechanic, Master Mechanic, Maintenance Technician, Maintenance Mechanic, Machine Adjuster, Fixer, Loom Fixer, Overhauler
STANDARDS ALIGNMENT
Activity #1:
TN mathematics standards
Literacy for Mathematical Proficiency - Write mathematical arguments.
〉 A1.N.Q.A.1 Use units as a way to understand problems and to guide the solution of multi-step problems; choose and interpret units consistently in formulas; choose and interpret the scale and the origin in graphs and data displays.
〉 A1.N.Q.A.2 Identify, interpret, and justify appropriate quantities for the purpose of descriptive modeling.
〉 M2.N.Q.A.1 Identify, interpret, and justify appropriate quantities for the purpose of descriptive modeling.
〉 A1.A.CED.A.2 Create equations in two or more variables to represent relationships between quantities; graph equations with two variables on coordinate axes with labels and scales.
〉 A1.F.IF.B.3 For a function that models a relationship between two quantities, interpret key features of graphs and tables in terms of the quantities, and sketch graphs showing key features given a verbal description of the relationship.
Activity #2
TN Principles of Engineering and Technology (C21H04) - Fundamental Sketching and Engineering Drawing
〉 9) Create a two-dimensional orthographic drawing incorporating labels, notes, and dimensions, using sketching/geometric construction techniques. Apply basic dimensioning rules and properly use different types of lines. The orthographic projections should include principle views of a simple object from top, front, and right sides.
TN Science and Engineering Practices
〉 Planning and carrying out controlled investigations
TN School Counseling Model and Standards Policy 5.103
〉 AS3. Develop and practice effective technology skills
〉 AS7. Demonstrate critical thinking and decision-making skills to make informed decisions
〉 CS4. Communicate effectively using oral, written, and listening communications skills
〉 SS8. Persevere through challenges to achieve goals
〉 SS4. Effectively collaborate with others, cooperate with diverse perspectives, and communicate effectively in a variety of situations
EDUCATOR RUBRIC
ITEM
Does Not Meet Expectations
Disassemble Student unable to disassemble their chosen device or student broke the device during disassembly.
Diagram/sketch Student did not complete a diagram or sketch of their object or their sketch was sloppily done and lacked detail.
Reassemble Student unable to reassemble the device.
Meets Expectations Exceeds Expectations
Student was able to disassemble the device.
Team Work Student did not work well in their team.
Student was able to complete a sketch or diagram of their device.
Student was able to disassemble the device and took specific detailed steps to catalogue the parts as they came off to ensure they could properly reassemble the device.
Student completed detailed diagram/ sketch of the device including sketching different parts of the device or sketching from different perspectives.
Student was able to mostly reassemble their device.
Student worked will in their team and contributed equally.
Student was able to completely reassemble their device without any extra parts left over.
Student worked well in their team, contributed equally and exhibited leadership.
ACTIVITY #1: REPAIR VS REPLACE
Introduction: In manufacturing, most systems, equipment, and machinery are operating 24 hours a day, 7 days a week. When you have a production schedule to meet, it is important that equipment function properly and does not break down causing a shutdown of the operation.
The main purpose for routine maintenance is to ensure that all systems, equipment, and machinery is operating at 100% efficiency at all times. By performing daily inspections, problems can be detected and corrected before they become a major problem and possibly shutdown the production line.
The decision to repair or replace equipment should be based on minimizing the total cost of the equipment to the business over its remaining lifetime. There are a number of factors to take into consideration when deciding whether to repair or replace equipment.
Activity Description: Students will analyze the data given to determine whether to repair or replace the trucks used to deliver products to customers.
Activity Procedure: Analyze the diagrams below then answer the questions. The charts below show information about repair and depreciation costs for the different delivery trucks a company uses to deliver products to customers
Average Transportation Repair Cost
Semi-Truck Box Truck Delivery Van
Average Transportation Depreciation Cost
Refer to the Repair Costs and Depreciation Costs graphs to answer these questions.
In general, the company will spend the most amount of money to keep their trucks running when they are how many years old? ____________________________
The company wants to buy a new truck, they are considering the following trucks:
Delivery Van, 5 years old
Box Truck, 5 years old
Semi-Truck, 3 years old
Delivery Van, 3 years old
Since money might be tight for the next few years, the company wants the truck that will have the lowest repair costs for the next three years.
Circle the truck above that the company should buy to get the lowest repair costs over the next three years.
The company has two Semi-Trucks, but needs to sell one. One is six years old and the other is eight years old. The company wants to keep the semi-truck that is past its year of highest total cost.
Consider both repair and depreciation costs and how it affects the company’s total worth. Which car, if any, should the company keep? _______________
The below statements are conclusions you might draw from the Repair Costs and Depreciation Costs graphs. Fill in the blank to complete each conclusion:
A truck loses most of its value in around the first ______________ years.
Most major truck repairs occur after the truck is ______________ years old. Which truck loses more value in the first year than the Box Truck?
Activity Discussion:
〉 How easily were you able to difficult to analyze the information in the diagrams to answer the questions?
〉 What are some of the factors a company should consider when making the decision to repair or replace a piece of equipment?
How do you think machinery repairs and replacement costs affect the overall production of the product?
Semi-Truck Box Truck Delivery Van
ACTIVITY #2: DISASSEMBLE & REASSEMBLE EQUIPMENT
Introduction: This activity challenges students to disassemble and reassemble an old machine or appliance to understand how Industrial Machinery Mechanics troubleshoot and repair machines and equipment.
Activity Description: In teams, students will disassemble and reassemble an old machine or appliance and identify what the device is, what it is used for, draw a sketch of the device, and document the steps to disassemble the device, and then follow the steps to reassemble the device.
Activity Procedure:
Separate into groups and discuss the following:
〉 What is the device?
〉 What is the device used for?
〉 Draw a sketch or diagram of the device.
Discuss these questions in your group and assign a team member to document the information below:
DISASSEMBLE THE DEVICE AND DOCUMENT EACH STEP
As a group, use the tools provided to disassemble your device and document the steps you took to disassemble the device:
USE THE WRITTEN STEPS TO REASSEMBLE THE DEVICE
Using your group’s documentation, reverse the process and re-assemble the machine or appliance.
Activity Discussion:
〉 How do you think this activity demonstrated the job of an Industrial Machinery Mechanic?
〉 Were you able to easily disassemble the machine and put it back together? If not, why?
How do you think Industrial Machinery Mechanics know how to disassemble, diagnosis, repair, and reassemble machinery?
